Technical Manual. Stepper controller SMCP33. NANOTEC ELECTRONIC GmbH & Co. KG Kapellenstraße 6 D Feldkirchen b.

Transcription

1 Stepper controller NANOTEC ELECTRONIC GmbH & Co. KG Kapellenstraße 6 D Feldkirchen b. Munich, Germany Tel. +49 (0) Fax +49 (0) info@nanotec.com

2 Editorial Editorial 2013 Nanotec Electronic GmbH & Co. KG Kapellenstraße 6 D Feldkirchen b. Munich, Germany Tel.: +49 (0) Fax: +49 (0) Internet: All rights reserved! MS-Windows 2000/XP/Vista are registered trademarks of Microsoft Corporation. Translation of original handbook Version/Change overview Version Date Changes New issue Technical data/inputs Pin assignment BLDC use Output circuits Signal states at the outputs 2 of 30 Issue: V1.5

3 About this manual About this manual Target group Important information Additional manuals This technical manual is aimed at designers and developers who need to operate a Nanotec stepper motor without much experience in stepper motor technology. This technical manual must be carefully read before installation and commissioning of the controller. Nanotec reserves the right to make technical alterations and further develop hardware and software in the interests of its customers to improve the function of this product without prior notice. This manual was created with due care. It is exclusively intended as a technical description of the product and as commissioning instructions. The warranty is exclusively for repair or replacement of defective equipment, according to our general terms and conditions; liability for subsequent damage or errors is excluded. Applicable standards and regulations must be complied with during installation of the device. For criticisms, proposals and suggestions for improvement, please contact the above address or send an to: info@nanotec.de Please also note the following manuals from Nanotec: NanoPro User Manual Configuration of controllers with the NanoPro software Programming manual Controller programming Command reference NanoJ COM interface The manuals are available for download at Issue: V1.5 3 of 30

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5 Contents Contents Editorial... 2 About this manual... 3 Contents Overview Commissioning Connections and circuits Pin assignment EVA evaluation board Inputs and outputs (I/O) Brake connection Ballast connection Encoder connection Stepper motor connection BLDC motor connection Power supply connection RS485 communication Operating modes Troubleshooting Technical data Index Issue: V1.5 5 of 30

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7 Overview 1 Overview Introduction The stepper motor controller is an extremely compact and cost-effective constant current final output stage with integrated closed loop current control. Due to the great capacity and functions available, it offers designers and developers a rapid and simple method of resolving numerous drive requirements with less programming effort. It is used for controlling standard stepper motors (including with attached encoders) or motors with integrated encoders or brakes. BLDC motors are also supported. The plug-in module can be integrated in complex device controllers with a minimum of additional development effort, especially for the direct and virtually noise-free and resonance-free control of the output stages via the microcontroller by means of the dspdrive method both in open loop and closed loop operation. In conjunction with the integrated NanoJ programming language based on the Java standard, complete sequencing programs can be implemented on the plug-in module that can be run autonomously without a superordinate controller. Variants Functions of the The is available in the following variants: : 2 A phase current -K: With a heat sink for 4 A phase current The stepper motor controller contains the following functions: Microstep -1/1 1/64 final output stage (step resolution of up to in motors with a step angle of 0.9 in 1/64 step mode) Closed loop current control (sinusoidal commutation via the encoder) Powerful DSP microprocessor for flexible I/O Sequence programs with NanoJ Rotation monitoring for optional encoder RS485 port for parameterization and control Network capability with up to 254 controllers The function of the digital inputs and outputs and the two analog inputs is freely configurable Easy programming with the NanoPro Windows software Closed loop current control (sinusoidal commutation via the encoder): In contrast to conventional stepper motor controllers where only the motor is actuated or the position adjusted via the encoder, sinusoidal commutation controls the stator magnetic field via the rotary encoder as in a servo motor. The stepper motor acts in this operating mode as nothing more than a high pole servomotor, i.e. the classic stepper motor noises and resonances vanish. As the current is controlled, the motor can no longer lose any steps up to its maximum torque. Issue: V1.5 7 of 30

8 Overview If the controller recognizes that the rotor is falling behind the stator field due to overload, adjustments are made with optimal field angle and increased current. In the opposite case, i.e. if the rotor is running forward due to the torque, the current is automatically reduced so that current consumption and heat development in the motor and controller are much lower compared to normal controlled operation. With dspdrive, the motor current is controlled directly by a digital signal processor. Unlike conventional ICs, which resolve the winding current measurement and the target current value with only 6 or 8 bit, the new dspdrive performs the entire control with a resolution of 12 bit. The parameters of the PI current controller can be adjusted to the motor and by the user as a function of the rpm. This has the following application advantages: Very smooth, low-resonance operation with a sinusoidal current in the windings, even at low speeds. Very good step angle precision and synchronicity, even in open loop operation. Three-phase stepper motors and BLDC motors can be controlled as well. Settings Rotation monitoring The integrated programming language NanoJ, based on the Java standard, means complete application programs can be realized on the drivers that can be executed independently without a higher-order controller. The programs can be created, compiled directly and written to the controller with the free NanoJEasy editor. More detailed information can be found in the separate programming manual. The operating behavior of the motor can be set and optimized according to individual requirements by setting the motor-related parameters. The parameters can be set using the NanoPro software and significantly reduce commissioning time. More detailed information on this can be found in the separate NanoPro user manual. Even if stepper motors do not lose steps during normal operation, the integrated rotation monitoring provides additional security in all operating modes, e.g. against motor stalling or other external sources of error. The monitoring function detects motor blockage or step loss after half a step at the most (for 1.8 stepper motors). Automatic error correction is possible after the drive profile is ended or between the travel profiles. 8 of 30 Issue: V1.5

9 Commissioning 2 Commissioning Requirements Commissioning of the stepper motor is described below. You will find the main "First Steps" here to start working rapidly with the if you are using the NanoPro software from a PC. You will find more detailed information in the separate NanoPro manual. If you want to work at a later time with a PLC or your own program, you will find the necessary information in the separate "Programming manual". Familiarize yourself with the stepper motor controller and the corresponding NanoPro control software before you configure the controller for your application. Procedure Proceed as follows to commission the controller: Step Action Note 1 Install the NanoPro control software on your PC. See the NanoPro separate manual. 2 Plug the into the motherboard (-EVA evaluation board). Download from Detailed information on the -EVA can be found in Section 3.2 -EVA evaluation board and under the Accessories/Electronics menu item on 3 Connect the controller to the stepper motor. Detailed information on connections can be found in Section 3 Connections and circuits. 4 Switch on the operating voltage (12 V DC V DC). 5 If necessary, install the converter driver for the converter cable ZK-RS485-RS232 or ZK-RS485- USB. 6 Connect the controller with your PC via the serial D-Sub 9 or the USB port of the -EVA motherboard. Use one of the following converter cables for this purpose: ZK-RS485-RS232 for connection to the serial port ZK-RS485-USB for connection to the USB port Download from in the Accessories/Converter menu item Order number: ZK-RS485-RS232 ZK-RS485-USB Issue: V1.5 9 of 30

10 Commissioning Step Action Note 7 Start the NanoPro software. The NanoPro main menu appears. 8 Select the <Communication> tab. 9 In the "Port" field, select the COM port to which the is connected. The number of the COM port to which the controller is connected can be found in the device manager of your Windows PC (System Control/System/Hardwar e). 10 Select the " bps" entry in the "Baudrate" selection field. 11 Check the current setting using the motor data sheet. Presettings: Phase current: 50% (current level) Phase current during idle: 25% (idle current) Under no circumstances may the current be set to a value higher than the rated current of the motor. 12 Select the <Movement Mode> tab. 13 Click on the <Test Record> button to carry out the pre-set travel profile. The connected motor operates with the pre-set travel profile (default travel profile after new installation). 14 You can now enter your required settings. For instance, you can enter a new travel profile. See the NanoPro separate manual. 10 of 30 Issue: V1.5

11 Connections and circuits 3 Connections and circuits 3.1 Pin assignment Pin assignment Issue: V of 30

12 Connections and circuits Description Pin no. Name Observations 1/2 GND Mass (0 V) 3/4 +V B Operating voltage +12 V DC V DC 5/6 GND Mass (0 V) 7/8 B/ Motor phases; For BLDC motors: 9/10 B A = V (red) 11/12 A/ 13/14 A A/ = U (yellow) B = W (black) 15/16 GND Mass (0 V) 17 Index track (I) Encoder, 18 Track (A) 19 Track (B) B/ = not connected V In BLDC motors: supply for hall sensors 21 Temp motor 22 Brake Brake output 23/24 Ballast Ballast output 25 RS-485 Rx RS-485 connection 26 RS-485 Rx+ 27 RS-485 Tx 28 RS-485 Tx+ 29/30 GND Mass (0 V) 31 Analogue In 1 Analogue input 1 ( 10 V V) 32 Analogue In 2 Analogue input 2 ( 10 V V) 33 Input 1 Digital inputs; 34 Input 2 For BLDC motors: 35 Input 3 Input 2 = Hall sensor H1 (blue) 36 Input 4 Input 3 = Hall sensor H2 (white) 37 Input 5 Input 4 = Hall sensor H3 (green) 38 Input 6 39 Input 7 40 Input 8 41 Output 1 Outputs 42 Output 2 43 Output 3 44 Output 4 45 Output 5 46 Output 6 47 Output 7 48 Output 8 49/50 GND Mass (0 V) 12 of 30 Issue: V1.5

13 Connections and circuits 3.2 -EVA evaluation board General information Board The -EVA evaluation board of Nanotec is a motherboard for the plug-in device card. It can be used for the rapid commissioning of four stepper motors via a pre-wired RS485 network and a PC connection. All inputs and outputs available in the are led to the outside via Phoenix Combicon connectors. In addition, an encoder or a brake can be connected. Issue: V of 30

14 Connections and circuits Connection diagram Note: The connection diagram is available for download on 14 of 30 Issue: V1.5

15 Connections and circuits 3.3 Inputs and outputs (I/O) Input circuits All digital inputs are designed for 5 V input signals. Note: The voltage must not exceed 5 V. It should drop below 2 V for safe switching off and be at least 4.5 V for safe switching on. Output circuits The outputs are a TTL outputs (5 V/max. 20 ma). To be able to test the output, an LED with a series resistance against earth can be integrated. The LED lights up when the output is active. Issue: V of 30

16 Connections and circuits Circuitry of hall sensors in BLDC mode The hall sensors of the BLDC motor are connected as shown in the following graphic: Function of the inputs Signal states at the outputs All digital inputs with the exception of the "Clock" input in the clock directional mode can be freely programmed using the NanoPro software (e.g. as a limit position switch, enable, etc.) and can be used for sequential control with NanoJ. Note: In BLDC mode, the inputs 2, 3 and 4 cannot be used for the configuration of the operating mode. A reconfiguration is not possible at this time. The "Analogue In 2" analog input currently can only be used by the programming language. All inputs can be configured for active-high" (PNP) or active-low" (NPN) with NanoPro. The following table shows the possible signal states at the outputs: (assignment: Output 1 = ready, Output 2 = running, Output 3 = error) Signal states Meaning Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output Rotation monitoring (error) or limit switch 0 1 Motor idle (waiting for new command) 1 0 Busy (control processing last command) 1 1 Reference point or zero point reached 1 Overtemperature The outputs can be freely programmed using the NanoPro software. Note: Output 3 is also used to display errors and when switching on the controller. 16 of 30 Issue: V1.5

17 Connections and circuits 3.4 Brake connection Function Parameters The brake output is used to control an external safety brake for the motor. This allows the holding torque and therefore the system stiffness to be increased further when necessary. Because the output is a TTL output, an additional controller component is needed. In NanoPro, the brake parameters can be configured in the <Brake> tab; see the separate manual on NanoPro. Example: Connection to -EVA On the -EVA motherboard shown in Section 3.2 -EVA evaluation board, the brake connections are located on the interfaces X8/ X14/ X21/ X Ballast connection Function Circuit on the motherboard The ballast output is used by the controller to indicate overvoltage at the supply. The motherboard should have a circuit that protects the controller against brief voltage peaks as can occur through the reverse feeding of the motors in the generator mode. The connection diagram of the evaluation board shows a version of the ballast circuit that conducts the excess voltage/energy to a resistor with the aid of a transistor, where it is converted to heat. This resistor is also referred to as the "Brake resistor" because the energy usually arises from braking of the motor. This protects the against destruction from brief overvoltage. The rating and cooling of the resistor determines how long it can convert the overvoltage before it becomes too hot and is destroyed. Issue: V of 30

18 Connections and circuits 3.6 Encoder connection Optional encoder An optional encoder can be connected to the stepper motor controller. By default, the closed loop control for a three-channel encoder is set up with 500 pulses/revolution in a 1.8 stepper motor. With an 0.9 stepper motor, you should use an encoder with 1000 pulses/revolution to achieve the same control quality. Depending on the application, it may make sense to use higher encoder resolutions (up to max pulses/revolution) to improve control quality or to use a lower resolution (min. 200 pulses/revolution) for low-cost applications or for step monitoring alone. The following encoder resolutions can normally be processed by the controller: 192, 200, 256, 400, 500, 512, 1000, 1024, 2000, 2048, 4000, Recommendation If possible, use Nanotec encoders with the order identifier WEDS/WEDL-5541 Xxx. If an encoder is not used, the "Disable" mode must be set in the <Error correction> tab in the "Rotation Direction Mode" selection menu. See the NanoPro separate manual. Using encoders with line drivers The encoders of the WEDL series with a line driver output an inverted signal in addition to the encoder signal; this leads to better interference immunity and is especially recommended for long lines lengths (> 500 mm) and neighboring interference sources. The differential signal can be evaluated with a line driver/encoder adapter. The SMCP controllers themselves currently cannot evaluate the differential signal, meaning that only the channels A, B and I need to be connected to perform position monitoring. We recommend shielding and twisting the encoder line to minimize interference with the encoder signal from the outside. 3.7 Stepper motor connection Connection cable The motor is connected to the with a 4-wire cable. Twisted wire pair cables with braided shields are recommended. Danger of electrical surges Mixing up the connections can destroy the output stage! See the data sheet of the connected stepper motor. Never disconnect the motor when operating voltage is applied! Never disconnect lines when live! Motor with 6 or 8 connections If you are using a motor with 6 or 8 connections, you need to connect the windings. The pin configuration for the motor can be found on the motor data sheet, which can be downloaded from 18 of 30 Issue: V1.5

19 Connections and circuits 3.8 BLDC motor connection A BLDC motor is connected to the controller as shown in the following graphic. To connect the hall sensors, see Section 3.3 "inputs and outputs (I/O)". 3.9 Power supply connection Permissible operating voltage The permissible operating voltage of the stepper motor controller lies within the range +12 to +48 V DC and must not exceed 50 V or undershoot 10 V. A charging condenser with minimum 4700 µf (10000 µf) must be provided for the operating voltage to prevent exceeding the permissible operating voltage (e.g. during braking). Danger of electrical surges Connect charging condensor with minimum 4700 µf! Connect a condenser with µf for motors with flange size 86x86 (series ST8918) or greater! An operating voltage > 50 V will destroy the output stage! Mixing up the connections can destroy the output stage! See the data sheet of the connected stepper motor. Never disconnect the motor when operating voltage is applied! Never disconnect lines when live! Accessories Appropriate power packs and charging condensers are available as accessories: Name Power pack Charging condenser Order identifier NTS-xxV-yA (xx=voltage: 12, 24 or 48 V, y=current: 2.5, 5 or 10 A) Information on the selection of the required power supply unit can be found in our FAQ on Z-K4700 or Z-K10000 Note: Further information about accessories can be found on the Nanotec website Issue: V of 30

20 Connections and circuits 3.10 RS485 communication in a network Up to 254 stepper motor controllers can be controlled in a network from a PC or PLC. This network connection is set up via the RS485 port. Example: Connection to -EVA On the -EVA motherboard shown in Section 3.2 "-EVA evaluation board", four stepper motors can be rapidly commissioned via a pre-wired RS485 network and a PC connection. For the PC connection, either a serial D-Sub 9 port (X29) or the USB port (X30) of the -EVA motherboard can be used. Use the following converter cable: ZK-RS485-RS232 for connection to the serial port ZK-RS485-USB for connection to the USB port 20 of 30 Issue: V1.5

21 Operating modes 4 Operating modes Introduction Depending on the travel profile, the motor can be operated using different operating modes. Due to the great capacity and functions available, it offers designers and developers a rapid and simple method of resolving numerous drive requirements with less programming effort. Select the required operating mode for each drive profile and configure the controller according to your requirements. More detailed information can be found in the separate NanoPro manual. Overview of operating modes and their areas of application Operation mode Relative positioning Absolute positioning Internal reference run External reference run Speed mode Flag positioning mode Application Use this mode when you wish to travel to a specific position. The motor travels according to a specified drive profile from a Position A to a Position B. During the internal reference run, the motor travels to an internal reference point (the index mark of the encoder) at the set minimum speed. During an external reference run, the motor travels to a switch connected to the reference input. Use this mode when you wish to travel with a specific speed (e.g. a conveyor belt or pump speed). In the speed mode, the motor accelerates with a specified ramp from the starting speed (start frequency "V Start") to the specified maximum speed (maximum frequency "V Normal"). Several inputs enable the speed to be changed onthe-fly to different speeds. The flag positioning mode offers a combination of the speed and positioning modes. The motor is initially operated in speed mode; when a trigger point is reached, it changes to the positioning mode and the specified setpoint position (relative to the trigger position) is approached. This operating mode is used for labeling, for example: the motor first travels with the set ramp to the synchronous speed of the conveyed goods. When the labels are detected, the preset distance (position) is traveled to apply the labels. Issue: V of 30

22 Operating modes Operation mode Clock direction mode, left Clock direction mode, right Clock direction mode Int. Ref. Clock direction mode Ext. Ref. Analog and joystick mode Analogue positioning mode Torque mode Application Use this mode when you wish to operate the motor with a superordinate controller (e.g. CNC controller). In the clock direction mode, the motor is operated via two inputs with a clock and a direction signal from a superordinate positioning control (indexer). Depending on the mode selected (Int. Ref./Ext. Ref.), the internal and external reference runs are supported. The motor is controlled in this operating mode simply with a potentiometer or a joystick ( 10 V to +10 V). Use this mode if you want to use the motor in a simple application: Setting a specific speed, e.g. via an external potentiometer, Traveling synchronously with a superordinate controller with analog output ( 10 V to +10 V). Use this mode when you wish to travel to a specific position. The voltage level at the analog input is proportionate to the desired position, thus enabling servo performance. Use this mode when you require a specific output torque independent of the speed as is the case in typical winding and unwinding applications. The maximum torque is specified via the analog input. Selecting the operating mode in NanoPro 22 of 30 Issue: V1.5

23 Troubleshooting Troubleshooting procedure 5 Troubleshooting Proceed with care during troubleshooting and error rectification to avoid damaging the controller. Danger of electrical surges An operating voltage > 50 V and incorrect connections can destroy the end stage. Never disconnect the motor when operating voltage is applied! Never disconnect lines when live! Possible error Error Possible cause Rectification Controller is not ready Data transmission to is not possible (communication error): Incorrect COM port selected. Communication cable not connected or interrupted (incorrect converter used). In the <Communication> tab, select the PC port to which you connected the (e.g. "COM-1"). The port used can be found in the device manager of your PC. Use the recommended RS232- RS485 converter from Nanotec: Order identifier: ZK-RS485-RS232 Transmission error Position error A non-existent motor number (module number) is set. The power supply of the is interrupted. Another open program is blocking the COM port to which the is connected. Inadmissible data was sent to the controller during the output of a travel profile. Multiple controllers with the same address are installed in the evaluation board. Data transmission to the is disturbed (sender or receiver are disturbed). A button was clicked while the controller was in error mode (position error or limit switch in normal operation). Set the correct module address. See the separate manual on NanoPro. Check voltage supply, switch on if necessary. Close down other programs on your PC. Click on the <Yes> button to stop the travel profile. The switches back to the "Ready" state. The data can then be resent to the controller. Install the controllers one after the other and assign a unique motor address to each. Check the possible causes for the transmission error and rectify the cause of the error. Click the <Yes> button in the error message; the error is reset. Issue: V of 30

24 Troubleshooting Error Possible cause Rectification Red LED on the lights up. Overtemperature of power electronics > 75 C Undervoltage Switch off controller and allow to cool. The error is reset when the is disconnected from the power supply unit. Check voltage supply. 24 of 30 Issue: V1.5

25 Technical data 6 Technical data Electrical connections Operating voltage V b DC 12 V to 48V ±4% Max. phase current Current drop RS-485 interface : nominal current 2 A, adjustable up to max. 3 A/phase -K (with heat sink): nominal current 4 A Adjustable 0 to 100% of phase current Baud (adjustable) 1 start bit, 8 data bits, 1 stop bit No parity Controller parameters Step modes Step frequency Position monitoring Full Step Half Step Quarter Step Fifth Step Eighth Step Tenth Step 32nd Step 64th Step Feed rate Adaptive microstep (1/128) 16 khz with a full step, corresponding multiples with a microstep (e.g. 1 MHz with 1/64) Max. input frequency, clock direction mode: 200 khz Automatic error correction to 0.9 only with optical encoder (e.g. WEDS5541 series) Inputs and outputs Inputs 8 digital inputs (5 V) Safe switch off: max. 2 V Safe switch on: min. 4.5 V 2 analog inputs Outputs 8 TTL outputs (0 switching, max. 5 V/25 ma) 1 brake output, 1 ballast output Issue: V of 30

26 Technical data Protective circuits dimensions Overvoltage and undervoltage Protection circuit for voltage > 50 V or < 10 V Max. heat sink temperature Approx. 80 C Ambient temperature 0 to 40 C -K dimensions (with heat sink) A complete set of datasheets is available for downloading at Mating connector/board holder, EADC types Mating connector: Inline plug-in unit, short: Encoding element between contact: of 30 Issue: V1.5

27 Technical data Overtemperature protection In the with a heat sink, the power drive of the controller is switched off at a temperature of approx. 75 C and is set to output 3. In the without a heat sink, the overtemperature protection of the driver component is activated at a temperature of approx. 130 C. The power drive of the controller is switched off and output 3 is set. After the controller is cooled and restarted, it becomes functional again. Temperature tests were performed under the following conditions: Operating voltage: 24 V/48 V DC Motor current: 71% (2 A), 100% (2.8 A), 150% (4.2 A) Operation mode: Full step speed mode, 25 rpm and 0 rpm Operating environment: Binder FED 53 temperature cabinet, circulated air at 100% fan speed Ambient temperature: 45 C Test motor: ST5918M6404 Measurement point: without heat sink: chip housing of driver component with heat sink: heat sink above driver component The following graphics show the temperature test results: Issue: V of 30

28 Technical data Operating voltage 24 V (without heat sink) Operating voltage 24 V (with heat sink) 28 of 30 Issue: V1.5

29 Technical data Operating voltage 48 V (without heat sink) Operating voltage 48 V (with heat sink) Issue: V of 30

30 Index Index A Accessories for voltage supply B Ballast connection BLDC... 16, 19 Brake C Closed loop current control... 7 E Encoder... 8, 18 External reference run H Hall sensors I Input circuits Inputs Internal reference run M O Operating modes Operating voltage Output circuits Outputs Overtemperature protection P Pin assignment Protective circuits... 26, 27 R Reference run Rotation monitoring... 8, 18 RS485 communication S functions... 7 V Variants... 7 Voltage supply Motor connection BLDC motor Stepper motor of 30 Issue: V1.5